Method for making soil conditioner

ABSTRACT

A method of making a landscaping mulch, using as its primary ingredient, spent stable bedding which has its primary ingredient ripe de bois softwood shavings. The result of the method is a mulch, particularly for landscaping applications, having a relatively high pH value, between 6.5 and 7.5, which is also useful for neutralizing the effects of acid rain. The method involves the steps of mixing agricultural manure in the range of 5%-25%, softwood shavings from spent stable bedding in an amount of greater than 60%, and when necessary, to augment carbon-to-nitrogen ratios, other ancillary ingredients in an amount less than 25%; producing a result by the mixing of ingredients, which has a carbon-to-nitrogen range from 100 to 200 parts of carbon to 1 part of nitrogen. Thereafter, the mixed ingredients are used to form piles, which are then over-saturated with water. Thereafter, liquid is percolated through the mixed ingredients, which liquid is expressed from the bottom of the pile by gravity. Thereafter, the pile is resaturated with the expressed liquid, now rich in tannin liquors, in order to provide a natural coloring agent for the material. Then the water flow is halted in order to allow biological activity to generate heat. Heat bakes-in the color and releases more tannins for extraction when liquid saturation is resumed. The foregoing process, beginning with resaturation, is repeated until the desired color is achieved.

This application is a continuation of Ser. No. 09/576,410, filed on May22, 2000. Now U.S. Pat. No. 6,264715.

FIELD OF THE INVENTION

This invention relates to methods for making soil conditoners, and moreparticularly to a method for coloring and converting of softwoodsshavings into a mulch for landscaping applications.

BACKGROUND OF THE INVENTION

In the field of producing mulch for landscaping applications, it ishighly desirable to produce a mulch with natural, dark color, and goodmoisture retention properties. It is known that many commonly producedmulches are artificially dyed to imitate natural colors. The dyes usedfor artificial coloration are known to shed water and/or inhibit waterabsorption. Furthermore, many of the dyes and emulsions used toartificially color mulch are known to contain ingredients which may beharmful when handled, or when leached into the soil and environment.

The attempt to produce mulch by artificially dying ingredients alsoincurs the use of specialty equipment, such as screeners, dryers, andthe like. The costs of such equipment ranges upwardly from $60,000 to$200,000 and above. Mulch produced with such dyes, emulsions, andequipment adds as much as $4.20 per cubic yard of finished material.

Additionally, many commercially produced mulches contain undesirableingredients, such as demolition debris, glass, plastic, creosoted wood,wood containing toxic preservatives, and some soil conditioners evencontain sewage waste products.

Additionally, because of the manner in which ingredients are handled andprocessed, many mulches contain weed seeds which are undesirable in alandscaping product.

A superior mulch and soil conditioner will be produced by a processwhich uses only natural, organic ingredients, has a natural, permanentdark color, has an attractive texture, has good moisture retentionproperties, is free of toxic materials, is free of weed seeds, is safefor humans, pets, and other living things, and qualifies in any organiccertification program.

The present invention embodies all of the aforementioned virtues inproduction and in the final product. A commonly used method forproducing mulch which most closely resembles this invention, Zeager U.S.Pat. No. 4,788,790, is referred to in order to illustrate the drawbacksof that process and the improvements of this invention. In that patent,Zeager recommends, as an ingredient, 20% bark, preferably oak bark.Also, Zeager states a preferred temperature of 65 degrees to 85 degreesF (18.3 degrees to 29.3 degrees C) in order to produce the dark colorfor the mulch. Furthermore, Zeager finds faster processing in thesummertime, and forms piles in long and low rows with a total volumeranging between 2800 and 9400 cubic yards. As may be seen from theforegoing, the bark used by Zeager is, of course, different than thecombination of manure-softwood shavings recommended in the presentinvention. Also, the low temperature range used by Zeager is much toolow to include biological activity as part of the manufacturing process.The recommendation by Zeager to perform his method in summer, avoids amore efficient processing during lower ambient temperatures with thepresent invention process. Furthermore, the conical shapes recommendedin the present invention process accounts for the difference in thequantity of heat generated, 160 degrees to 200 degrees F (70 degrees to93 degrees C) with the present invention, as compared to 65 degrees to85 degrees F (18.3 degrees to 29.3 degrees C) noted by Zeager. Stillfurther, the use of a crater and concentric troughs in the pilesrecommended in the present invention process, serves to increase theuniformity of saturation of liquid within the piles and propercompaction of the piles, when compared to the Zeager process. Lastly,the present invention produces a final pH value which is “sweet”, andthis is beneficial when used.with many types of landscaping plantings,whereas the same result is not achieved by Zeager.

OBJECTS AND SUMMARY OF THE INVENTION

Accordingly, a primary object of the present invention is to provide aprocess for producing mulch which is safe, non-toxic, weed-free, is ableto qualify in organic certification programs, and results in mulch whichis natural and darker colored for land-scaping applications.

A further object of the present invention is to provide a method forproducing mulch which is lower in cost for equipment and ingredientsthan the methods presently available.

A further and more particular object is to provide a method forproducing mulch resulting from the use of proper moisture andtemperature levels, wherein biological activity is promoted in order tokill weed seeds and bake-in the desired color, which ranges from brownto black.

These and other objects of the invention are featured in a method forproducing mulch which utilizes ripe de bois, softwood shavings that havebeen used as a bedding in horse stables and/or cow barns. Spent beddingingredients are mixed with approximately 10% to 20% agricultural manure,by volume, so that a carbon-to-nitrogen ratio ranging from 100 to 200parts carbon to 1 part nitrogen is. achieved. Other ancillaryingredients can be used in the mixture, but not to exceed 25% of thevolume. Accordingly, the softwood shavings, by volume, constitute atleast 60% of the mixture. Piles are formed of the mixed ingredients toachieve maximum compression, saturation, and optimal heat generation.The shapes of the piles are made in the form of cones, with concentrictroughs and a crater truncating the top of the cone. The crater isformed so that approximately 25% of the full height of the cone isremoved, with a pre-truncation height of 34 to 47 feet. The basediameter of the cone ranges from 68 to 94 feet, and a volume range of1500 to 4000 cubic years.

After the piles are formed in such sizes and shapes, they are thenover-saturated with water, which then percolates through the mixedingredients and is expressed from the bottom of the pile by gravity, andpooled. The expressed liquid at the base of the cone, which is now richin tannin liquors, is used to resaturate the pile and so provides thenatural coloring agent for the material. Then, water flow is halted forinherent heat to generate by biological activity in the absence of waterflow. The heat bakes-in the color and releases more tannins forextraction when liquid saturation is resumed. The process ofresaturation and halting of the water flow to generate heat bybiological activity is repeated until the desired color is achieved.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features and advantages of the present invention willbecome apparent by reference to the following detailed description ofthe preferred, but nonetheless illustrative, embodiment of the presentinvention, with reference to the accompanying drawing, wherein:

FIG. 1 is a representation of the pile used to place the mixedingredients, according to the invention method, so that such ingredientsmay be first over-saturated with water, and which pile has side-wallconcentric troughs and a crater at the top thereof to achieve maximumcompression, saturation and heat generation according to the presentinvention method;

FIG. 2 shows the slightly inclined grade upon which the pile is placed,with a dammed perimeter beyond the bottom edge of the pile forexpressing and pooling the liquid resulting from the invention method;and

FIG. 3 is a block diagram representing steps of the method according tothe present invention.

DETAILED DESCRIPTION OF THE METHOD ACCORDING TO THE PRESENT INVENTION

According to the present invention, spent stable bedding is collectedand used to form a mixture, including, by volume, no more than 5%-25%agricultural manure in relation to softwood shavings. Usually the manurewill be in the range of 10% to 20%, by volume, but when harvestingagricultural manure from high-profile show barns, manure content maydrop below 5%. When agricultural manure content is harvested from otherstables the manure content can be as high as 20%-25%, but, in any case,proper mixing with the softwood shavings is essential.

Of the total volume, at least 60% should be ripe de bois softwoodshavings, or other softwood chips, plus any other ancillary ingredients,such as soiled cow bedding, grass clippings, spoiled silage or greenchop, and agricultural manure if nitrogenous supplements are called for;and straw, sawdust, or any organic woodchip or shaving of homogenoussize when carbonaceous materials are called for. This is to achieve aratio of carbon-to-nitrogen ranging from 100 to 200 parts carbon to 1part nitrogen.

The ingredients are well mixed to form that ratio, and thereafter, pilesare formed to achieve maximum compression, saturation, and optimal heatgeneration. Such form for the pile is shown in FIG. 1, generallydesignated 10, wherein the total volume is shown to range from 1500 to4000 cubic yards, initially. After the conical pile is formed, crater 16is then formed at the top of the pile 10, as shown by ghost lines. Therim of this crater should be at approximately 75% of the height of theoriginal pile, with the original height 14 being approximately 34 to 47feet before the crater is formed. The volume range is adhered to byforming the piles, each with a base diameter of 68 to 94 feet. Dependingon the exact constituent ingredients used, and their moisture content atthe time of pile formation, the angle of the slope of the cone shouldoptimally be 45 degrees. In forming the piles, if an elevator is used,each pile will have a more uniform shape in comparison to a pile formedby equipment such as a front-end loader or bulldozer. In either case,the proportions of the pile may vary as equipment and location dictate.However, slight variations in the shape of the pile will not reduce theoverall effectiveness of the method, according to this invention.

Additionally, concentric troughs 12, ringing the side wall of the pileat regular intervals, allow run-off spilling from the crater at the topto more evenly saturate the pile. The number of concentric troughs mayrange between three and five depending upon the volume of the pile.

For the purpose of pooling expressed liquids, such piles are formed,each on ground graded to a gradual inclination to a formed perimeter damat the low end of the slope. The ground should be a non-poroussubstrate, as indicated in FIG. 2, or, if substrate upon which piles areformed is porous, such ground should be lined with clay or otherimpervious material. The pooling indicated in FIG. 2 enables the furtheruse of liquid tannins formed by the pile. Additionally, liquid tanninsmay be stored in a tank, or series of tanks, for subsequent use.

As will be indicated hereinafter, after forming a pile, water orpreviously saved tannin liquors are pumped onto the pile until completesaturation occurs. In other words, pumping continues beyond saturation,from the liquid that is expressed from the bottom of the pile, until theharvested amount is sufficient to resaturate the pile. It should also bestated that resaturation is best achieved by pumping the pooled tanninliquors back to the top of the pile and filling the crater.

The application of water or available tannin liquors ceases when thepile has become fully saturated. The moisture of the pile slowly reducesand eventually falls through the 70% to 40% range to support biologicalactivity. Temperature is monitored with a probe thermometer until amaximum temperature of 200 degrees F (93 degrees C) is achieved. At thistemperature, biological activity ceases, and additionally, most weedseeds are killed off. When moisture falls below 40% and/or temperatureexceeds 200 degrees F (93 degrees C.), resaturation begins.

This process of saturation and monitoring should be repeated over andover again until desired coloration is achieved from the recirculationof tannin liquors. To achieve optimum dark brown, or black colors, thepile is mixed and reformed at least once.

Because this is normally an outdoor activity, subject to changes inseasonal temperature and humidity, the time it takes to reach a desiredtemperature will vary, as will the length of time a pile remains at aparticular moisture level. Although the coloring process worksthroughout the year, experience has shown it works quickest when ambienttemperatures are at their lowest, so that less time will be required toachieve desired color. When final desired color is reached, the pileshould be either covered or broken down for distribution.

The final saturation of the pile yields the most potent, tannin richliquids, and as much of this as possible should be harvested and storedto begin the saturation of a new pile.

In order to provide a more complete understanding of the presentinvention, a series of method steps, and alternatives, will now beprovided, with reference particularly to FIG. 3.

Minimally, ripe de bois, in an amount greater than 60%, and agriculturalmanure are mixed to produce a carbon-to-nitrogen ratio of 100 to 200parts carbon to 1 part nitrogen. The mixture is then arranged in piles,on a substrate of graded ground, or clay lined ground, as shown in FIGS.1 and 2. The crater at the top of the piles is filled with water, andindeed, the piles are oversaturated with water, so that liquidpercolates through the mixed ingredients to be expressed from the bottomof the pile by gravity, and then pooled against dam 18, as shown in FIG.2. The pooled liquid, which is rich in tannin liquors, is used toresaturate the pile through the crater 16, in order to color the mixedmaterial. When the desired color is reached, the application of waterand tannin liquors ceases with the pile becoming fully saturated. Themoisture of the pile slowly reduces, falling through the 70% to 40%range so that biological activity is started. When the temperature of200 degrees F (93 degrees C) is achieved, biological activity ceases,and as moisture falls below 40%, and/or temperature exceeds 200 degrees(93 degrees C), resaturation begins. During that process, the halt ofwater flow enables heat generated by biological activity to bake-in thecolor and release more tannins for extraction when resaturation resumes.The process is repeated until the desired color is achieved.

As an alternative, if the carbon-to-nitrogen ratio is not achievedwithout ancillary ingredients, such ancillary ingredients, ashereinbefore indicated, are used in an amount less than 25%, by volume,to enable the mixture to achieve the desired ratio.

The foregoing is intended to illustrate the present invention, itsalternative embodiments, and the ranges of sizes and amounts asrecommended. Such is not intended to limit this invention, which is tobe accorded the scope of the following claims:

What is claimed is:
 1. A method for making a soil conditioner,comprising: mixing softwood shavings and agricultural manure to form,after mixing, a material having a carbon-to-nitrogen ratio of up to 200parts of carbon to one part of nitrogen; forming a pile of the materialon a ground surface, wherein a volume of the pile is sufficient tosustain a pile temperature that exists during generation of heat in thepile by biological activity, and wherein the pile temperature is atleast 160° F.; flowing liquid that includes water into the pile toover-saturate the pile, wherein the liquid gravitationally percolatesthrough the pile and is collected after exiting the pile, and whereinthe collected liquid includes tannin that has been extracted from thepile by the percolating liquid; halting the flowing of liquid;generating heat in the pile by the biological activity in an absence ofthe flowing of liquid, wherein the heat bakes in the color of the pileat the pile temperature; and if the color of the pile is not as dark asdesired, then iteratively repeating the flowing, halting, and generatinguntil the color of the pile is as dark as desired, wherein the iterativerepeating of the flowing includes flowing liquid from the collectedliquid.
 2. The method of claim 1, wherein the carbon-to-nitrogen ratiois in a range of 100 to 200 parts of carbon to one part of nitrogen. 3.The method of claim 1, wherein the volume of the pile is between 1500cubic yards and 4000 cubic yards.
 4. The method of claim 1, wherein thepile temperature is in a range of 160° F. to 200° F.
 5. The method ofclaim 1, further comprising forming a dam proximate the base of the pilefor containing the collected liquid.
 6. The method of claim 1, whereinthe softwood shavings are at least 60% of the material by volume, andwherein the agricultural manure is no more than 25% of the material byvolume.
 7. The method of claim 6, wherein the agricultural manureconsists essentially of horse manure.
 8. The method of claim 6, whereinthe mixing further includes mixing at least one additional nitrogenousmaterial.
 9. The method of claim 6, wherein the mixing further includesmixing at least one additional carbonaceous material.
 10. A method formaking a soil conditioner, comprising: mixing softwood shavings andagricultural manure to form, after mixing, a material having acarbon-to-nitrogen ratio of up to 200 parts of carbon to one part ofnitrogen; forming a pile of the material on a ground surface, whereinthe pile has a volume between 1500 and 4000 cubic yards; flowing liquidthat includes water into the pile to over-saturate the pile, wherein theliquid gravitationally percolates through the pile and is collectedafter exiting the pile, and wherein the collected liquid includes tanninthat has been extracted from the pile by the percolating liquid; haltingthe flowing of liquid; generating heat in the pile by biologicalactivity in an absence of the flowing of liquid, wherein the heat bakesin the color of the pile at a pile temperature of at least 160° F.; andif the color of the pile is not as dark as desired, then iterativelyrepeating the flowing, halting, and generating until the color of thepile is as dark as desired, wherein the iterative repeating of theflowing includes flowing liquid from the collected liquid.
 11. A methodfor making a soil conditioner, comprising: mixing softwood shavings andagricultural manure to form, after mixing, a material having acarbon-to-nitrogen ratio of up to 200 parts of carbon to one part ofnitrogen; forming a pile of the material on a ground surface, wherein abounding outer surface of the pile slopes upward away from the groundsurface and inward toward an interior of the pile, and wherein the pilehas a volume between 1500 and 4000 cubic yards; flowing liquid thatincludes water into the pile to over-saturate the pile, wherein theliquid gravitationally percolates through the pile and is collectedafter exiting the pile, and wherein the collected liquid includes tanninthat has been extracted from the pile by the percolating liquid; haltingthe flowing of liquid; generating heat in the pile by biologicalactivity in an absence of the flowing of liquid, wherein the heat bakesin the color of the pile at a pile temperature of at least 160° F.; andif the color of the pile is not as dark as desired, then iterativelyrepeating the flowing, halting, and generating until the color of thepile is as dark as desired, wherein the iterative repeating of theflowing includes flowing liquid from the collected liquid.
 12. A methodfor making a soil conditioner, comprising: mixing softwood shavings andagricultural manure to form, after mixing, a material having acarbon-to-nitrogen ratio of up to 200 parts of carbon to one part ofnitrogen; forming a pile of the material on a ground surface, wherein abounding outer surface of the pile slopes upward away from the groundsurface and inward toward an interior of the pile, wherein at least onecavity is formed at a top of the pile, and wherein the pile has a volumebetween 1500 and 4000 cubic yards; flowing liquid that includes waterinto the pile including into the at least one cavity to over-saturatethe pile, wherein the liquid gravitationally percolates through the pileand is collected after exiting the pile, and wherein the collectedliquid includes tannin that has been extracted from the pile by thepercolating liquid; halting the flowing of liquid; generating heat inthe pile by biological activity in an absence of the flowing of liquid,wherein the heat bakes in the color of the pile at a pile temperature ofat least 160° F.; and if the color of the pile is not as dark asdesired, then iteratively repeating the flowing, halting, and generatinguntil the color of the pile is as dark as desired, wherein the iterativerepeating of the flowing includes flowing liquid from the collectedliquid.
 13. A method for making a soil conditioner, comprising: mixingsoftwood shavings and agricultural manure to form, after mixing, amaterial having a carbon-to-nitrogen ratio of up to 200 parts of carbonto one part of nitrogen; forming a pile of the material on a groundsurface, wherein a bounding outer surface of the pile slopes upward awayfrom the ground surface and inward toward the mass of the pile, whereinat least one cavity is formed at a top of the pile, wherein at least onetrough is formed around the bounding outer surface of the pile, andwherein the pile has a volume between 1500 and 4000 cubic yards; flowingliquid that includes water into the pile including into the at least onecavity to over-saturate the pile, wherein the liquid gravitationallypercolates through the pile and is collected after exiting the pile, andwherein the collected liquid includes tannin that has been extractedfrom the pile by the percolating liquid; halting the flowing of liquid;generating heat in the pile by biological activity in an absence of theflowing of liquid, wherein the heat bakes in the color of the pile at apile temperature of at least 160° F.; and if the color of the pile isnot as dark as desired, then iteratively repeating the flowing, halting,and generating until the color of the pile is as dark as desired,wherein the iterative repeating of the flowing includes flowing liquidfrom the collected liquid.